System and method for variable perforation profiles in a stack of lottery tickets

ABSTRACT

A method and associated system are provided for producing a perforation line between adjacent lottery tickets in an automated production line wherein a substrate having lottery tickets printed thereon is conveyed through a perforation station in the production line. A perforation machine in the line is controlled to define a perforation line between the adjacent lottery tickets. The controlling process includes inputting control variables into a controller associated with the perforation machine, the control variables relating to conditions that determine a desired perforation profile of the perforation line. The controller programs the perforation machine with a specific perforation profile for the perforation line that is generated based on the entered control variables, and changes the perforation profile upon inputting of different values for the control variables. The perforation profile is specifically tailored to the control variables between different ticket production runs, or between tickets in the same ticket production run.

PRIORITY CLAIM

The present application is a Divisional Application of U.S. applicationSer. No. 15/188,452, filed Jun. 21, 2016.

BACKGROUND

Instant scratch-off lottery tickets are generally supplied to retailvending locations in the form of individual rolls or folded packs (alsoreferred to as “packs” or “books”) of interconnected tickets, whereinperforation lines separate the ends of adjacent tickets. The common edgebetween adjacent tickets extends perpendicular to the top side andbottom side of each ticket. The tickets include any manner of indiciaand graphics, as well as a play area wherein one or more game symbolsare covered with a scratch-off coating. For dispensing, the lead ticketis torn from the pack or roll along the perforation line. The packs orrolls may be loaded into a dispenser wherein the leading ticket ispulled through a dispensing slot prior to being separated.

The scratch-off lottery tickets are typically mass produced in ahigh-speed production line that includes a perforating machine thatdefines the perforation line between adjacent tickets. With theconventional machinery and methods, however, the perforation lineprofile is defined by the mechanical cutter profile and cannot varyunless the manufacturing line is stopped and the cutter is exchanged foranother that produces a different perforation profile. Even betweendifferent ticket production runs, it is a relatively complicated andtime consuming procedure to change out the mechanical cutter at theperforation station, which may be necessary when a change is made in thepaper stock to be processed into the lottery tickets. Thus, theinability to quickly and reliably change perforation profiles eitherbetween production runs or mid-stream of a production run is aparticular disadvantage with conventional systems and methods.

The present invention provides a solution to the problem noted above, aswell as adding additional functionalities to the perforation process inlottery ticket production lines.

SUMMARY

Objects and advantages of the invention will be set forth in part in thefollowing description, or may be obvious from the description, or may belearned through practice of the invention.

In accordance with aspects of the invention, a method is provided forproducing a perforation line between adjacent lottery tickets in anautomated production line. In a particular embodiment, the lotterytickets are instant scratch-off tickets. The method includes conveying asubstrate, such as a paper stock, through a perforation station in theproduction line, wherein the substrate has individual lottery ticketindicia printed thereon such that a continuous stream of adjacentlottery tickets oriented end-to-end are conveyed through the perforationstation. The substrate may have a plurality of rows of such tickets,wherein the rows are subsequently separated in a downstream slitterstation prior to packaging the tickets. A perforation machine at theperforation station is controlled by a controller to define aperforation line between the ends of adjacent lottery tickets.

This control process includes inputting one or more control variablesinto the controller, wherein the control variables relate to conditionsthat determine a desired perforation profile of the perforation line.The controller programs the perforation machine with a specificperforation profile for the perforation line that is generated based onthe entered control variables. The controller changes the perforationprofile upon inputting of different values for the control variables.The perforation profile can thus be specifically tailored to the controlvariables between different ticket production runs, or between ticketsin the same ticket production run.

In a particular embodiment, the control variables relate to particularenvironmental conditions expected at a dispensing location of thelottery tickets being produced, such as one or both of temperature andhumidity.

In another embodiment, the control variables may relate tocharacteristics of a substrate stock on which the lottery tickets areprinted in the production line, such as the weight of the paper, fibercontent, coatings, and the like.

In still another embodiment, the control variables relate to acombination of the particular environmental conditions expected at adispensing location of the lottery tickets and characteristics of asubstrate stock on which the lottery tickets are printed in theproduction line.

Different perforation profiles may be pre-generated (e.g., by thecontroller or another computer) for specific values of the controlvariables and stored in an electronic library that is accessible by thecontroller. The controller can then select one of the pre-generatedperforation profiles that is a closest match for the input controlvariables. The controller can use the pre-generated profile, or furthermodify the pre-generated profile based on the input control variables.

A real-time feedback loop may be incorporated in the process to detectdeviations from the pre-generated profiles and modify the perforationmachine operating parameters accordingly.

In a desirable embodiment, the perforation machine is a laserperforation machine having one or more laser perforation heads that arecontrolled by the controller for producing the different perforationprofiles.

The invention also encompasses a system for implementing the methodsdescribed above. For example, a system is provided for producing aperforation line between adjacent lottery tickets in an automatedproduction line wherein a substrate is conveyed through a perforationstation in the production line, the substrate having individual lotteryticket indicia printed thereon such that a continuous stream of adjacentlottery tickets oriented end-to-end are conveyed through the perforationstation. The system includes a perforation machine at the perforationstation to define a perforation line between the ends of the adjacentlottery tickets. A controller is in communication with the perforationmachine and is configured to: receive inputted control variables thatrelate to conditions that determine a desired perforation profile of theperforation line; program the perforation machine with a specificperforation profile for the perforation line that is generated based onthe entered control variables; reprogram the controller with a differentperforation profile upon receipt of different values for the controlvariables; and specifically tailor the perforation profiles to thecontrol variables between different ticket production runs, or betweentickets in the same ticket production run.

In a desirable embodiment of the system, the perforation machine is alaser perforation machine having one or more laser perforation headsthat are controlled by the controller for producing the differentperforation profiles.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure including the best mode of practicing theappended claims and directed to one of ordinary skill in the art is setforth more particularly in the remainder of the specification. Thespecification makes reference to the appended figures, in which:

FIG. 1 is an operational diagram of a lottery ticket production linethat incorporates a perforation station in accordance with the presentinvention;

FIG. 2 is a diagram of a substrate having multiple rows of lotterytickets and perforation lines across the substrate that separate theadjacent ends of the lottery tickets;

FIG. 3 is a block diagram of a perforation system in accordance withaspects of the invention;

FIG. 4 is a block diagram of an embodiment of a laser perforationsystem;

FIG. 5 is a top view of interconnected lottery tickets having a firsttype of perforation profile; and

FIG. 6 is a top view of interconnected lottery tickets having a secondtype of perforation profile.

DETAILED DESCRIPTION

Reference will now be made in detail to various and alternativeexemplary embodiments and to the accompanying drawings, with likenumerals representing substantially identical structural elements. Eachexample is provided by way of explanation, and not as a limitation. Infact, it will be apparent to those skilled in the art that modificationsand variations can be made without departing from the scope or spirit ofthe disclosure and claims. For instance, features illustrated ordescribed as part of one embodiment may be used on another embodiment toyield a still further embodiment. Thus, it is intended that the presentdisclosure includes modifications and variations as come within thescope of the appended claims and their equivalents.

As mentioned, the present invention relates to method and systemembodiments for producing a perforation line between adjacent lotterytickets in an automated production line. In a particular embodiment, thelottery tickets are instant scratch-off tickets. The present inventionappreciates a concept not recognized or practiced in the industry,namely that there is no one universal perforation profile well-suitedfor all types of paper substrates or environmental conditions in whichthe tickets are eventually dispensed.

The perforation profile is the pattern and/or size of the holes or slitsdefined through the substrate along the perforation line. The greaterthe number or size of the holes or slits, the lesser amount of intactsubstrate remains, resulting in a weaker perforation line. Thus, theperforation profile dictates the amount of “tear” force necessary toseparate a leading ticket from the remainder of the pack or roll, or inother words, the strength of the perforation line. The perforation lineneeds to have adequate strength to ensure that the tickets remainattached under all anticipated conditions. Perforation failures whereintickets prematurely separate within a pack or roll result in numerousundesirable events. For example, if the pack or roll is loaded into adispenser, the dispenser bin must be unlocked to retrieve and thread thedisconnected ticket through the dispensing slot. Loading of new packsinto a dispenser wherein the tickets have separated at one or moreperforation lines results in multiple mini-packs that must be loaded ina particular order to ensure sequential serial number dispensing. Thesemini-packs are usually taped together at the failed perforation lines.Consumers are wary of a “new” ticket that has been taped to anotherticket, and often refuse to purchase the questionable ticket. Separationof the tickets also brings into question accountability issues.

At the same time, the perforation lines must not be so strong as torequire excessive tearing force to separate the tickets. This excessiveforce often results in tickets tearing at locations other than along theperforation line, as well as leaving a jagged edge along the separatedperforation line. In certain sectors, the industry appears to be turningto automated, motor-driven dispensers wherein the tickets areautomatically metered out of a dispenser bin. In most cases, thistechnology relies on an edge sensor to detect the leading edge of aticket being dispensed, wherein the defined length of the ticket is thendispensed by the motor being driven for a time corresponding to thedefined length. A jagged edge resulting from a faulty perforation linecan “fool” the sensor, resulting in too little or too much of a motorrun time. As more and more tickets are dispensed, this issue compoundsitself.

With the present system and method embodiments, certain controlvariables are recognized as affecting characteristics of the ticketsubstrate, and thus the strength of a given perforation profile. Forexample, one such control variable is humidity, more particularly thehumidity at the location where the tickets are dispensed. With papersubstrates in particular, a higher humidity essentially causes thesubstrate to absorb moisture and swell. This swelling of the stockmaterial along the perforation line generally results in a greater tearstrength to separate the tickets along the perforation line.

Another control variable is temperature, more particularly thetemperature at the location where the tickets are dispensed. With papersubstrates in particular, a higher temperature generally causes thetickets to become relatively more brittle, which results in a weakerperforation line.

Still another control variable is the type, content, thickness, ordensity of the substrate material. For a given perforation profile, athicker or more dense substrate requires a greater tear strength toseparate the tickets along the perforation profile. Likewise, thesynthetic fiber material versus pulp fiber material content of thesubstrate will affect the necessary tear strength. Certain pulp fibersproduce a stronger paper stock as compared to other types of pulpfibers.

In accordance with aspects of the present system and method embodiments,values for one or more of these control variables are determined andused to tailor a perforation profile for a particular type of lotteryticket (e.g., type of substrate) and/or for anticipated environmentalconditions at the location the tickets will be dispensed.

FIG. 1 depicts an exemplary production line 10 for manufacturing instantscratch-off lottery tickets that may be configured with aspects of thepresent invention. This particular production line 10 is presented forillustrative purposes only and to place the invention in an exemplaryoperating environment. It should be appreciated that the present methodsand systems are not limited to any particular production lineconfiguration.

Still referring to FIG. 1, a substrate 14 on which the lottery ticketsare to be printed is delivered to an unwind station, typically in theform of rolls, with the unwind station including a suitable webtensioning device. The substrate is then conveyed to a first printingstation 16 that includes multiple printing machines for applying one ormore security lower security layers (e.g. a black layer) to thesubstrate.

The substrate 14 is then conveyed to second printing station 18 thatincludes multiple printing machines for applying any desired manner ofdisplay images, confusion patters (e.g. Benday patterns), or additionalcoatings over the security layers for each lottery ticket.

The substrate 14 is then conveyed to a secure imaging station 20, whichmay include a plurality of printing/imaging machines in a highly securedroom, wherein the game data indicia is printed on each of the ticketsand a scratch-off layer of material is applied over the game dataindicia. The tickets are conveyed from the secure imaging room throughan “E-Beam” clear coating station 22 wherein a coating is applied andcured to protect the game play data. Ultimately, the perforation profileis synchronized with the data and other indicia printed on the tickets.

The substrate 14 is then conveyed through a security coatings station 24wherein a plurality of printing machines apply one or more securingcoatings over the scratch-off layer.

The substrate 14 is then conveyed through an additional printing station26 wherein any manner of graphics are printed over the scratch-off layerand/or non-game play areas of each ticket.

The substrate 14 is then conveyed through a gloss coat applicationmachine 30.

From the gloss coat station 28, the substrate 14 is conveyed through aperforation station 30 configured in accordance with the invention (anddescribed in greater detail below). At this station, perforation linesare defined in the substrate transverse to the longitudinal travellingdirection of the substrate 14. As is well understood, the perforationline defines a separation line between adjacent ends of interconnectedtickets.

The perforated substrate 14 is then conveyed through an RTM (“Real TimeMarking”) station 32 where press personnel watch/inspect the websubstrate while printing for quality control issues.

The substrate 14 is then conveyed through a “Lead Press” station 34,which includes the main press console. This is the station where a “leadpress man” essentially controls the entire press operation.

Finally, the substrate 14 is brought to a rewind station 36 wherein theperforated substrate 14 with multiple rows of lottery tickets printedthereon is wound back into a roll package. From there, the rolls areeventually transported to additional processing stations wherein thesubstrate 14 is unwound, conveyed through a slitter wherein theindividual rows of interconnected and perforated tickets are separate.The individual rows of tickets are then conveyed through a foldingstation wherein the tickets are folded in a Z-pattern into individualpacks prior to being wrapped and sealed.

FIG. 2 depicts a partial section of the web 14 after passing through theperforation station 30. A plurality of rows 55 of individual lotterytickets 52 are printed on the substrate 14. The ticket rows 55 haveshared sides 57 that are delineated by any manner of graphics, alignmentmarks, etc. The rows 55 are eventually separated at the sides 57 by thedownstream slitter. The individual tickets 52 within each row haveadjacent ends 54 defined by the perforation lines 58.

FIG. 3 depicts a system and method 50 in accordance with the inventionimplemented at the perforation station 30. The substrate 14 is conveyedthrough the perforation station 30 in the production line, wherein thesubstrate 14 has individual lottery ticket indicia printed thereon suchthat a continuous stream of adjacent lottery tickets 52 (FIG. 2)oriented end-to-end are conveyed through the perforation station 30. Aperforation machine 56 at the perforation station 30 is controlled bycontroller 62 to define a perforation line 58 (FIG. 2) between theadjacent lottery tickets. This control process includes inputting one ormore control variables 60 into the controller 62. The control variables60 relate to conditions that determine a desired perforation profile ofthe perforation lines 58. The controller 62 programs the perforationmachine 56 with a specific perforation profile 64 (FIGS. 5 and 6) forthe perforation line 58 that is generated based on the entered controlvariables 60. The controller 56 changes the perforation profile 64 uponinputting of different values for the control variables 60. Thus,perforation profile 64 is specifically tailored to the control variables60 between different ticket 52 production runs, or between tickets 52 inthe same ticket production run.

As discussed above, the control variables 60 may relate to particularenvironmental conditions expected at a dispensing location of thelottery tickets being produced, such as temperature and humidity. Thus,tickets 52 produced for sale in a relatively dry or arid location mayhave a different perforation profile 58 as compared to tickets intendedfor sale in a humid coastal location, and so forth.

In addition, or alternatively, the control variables 60 may relate tocharacteristics of the substrate 14 stock on which the lottery ticketsare printed in the production line, such as the thickness, density,composition, and so forth, of the stock that affect the strength of theperoration profile. For example, the control variables 60 may relate toa combination of particular environmental conditions expected at adispensing location of the lottery tickets and characteristics of asubstrate 14 stock on which the lottery tickets are printed in theproduction line.

The method may include generating a plurality of different perforationprofiles 60 for specific values of the control variables 60 and storingthese pre-generated profiles 64 in an electronic library 66 that isaccessible by the controller 62. With this configuration, the controllerneed not generate the profile 64 upon receipt of each set of controlvariables, but can select the stored profile 64 that is the closestmatch for the values of the input control variables 60. The controllercan program the perforation machine 56 directly with the retrievedprofile 64, or may further modify the profile 64 based the input controlvariables 60.

In a particular embodiment, the perforation machine 56 is acomputer-controlled laser perforation machine 68, as depicted in FIG. 4.Commercial laser perforators are available, and it is contemplated thata number of these readily available machines 68 may be modified andconfigured to operate in a lottery ticket production line in accordancewith aspects of the invention discussed herein. For example, FIG. 4depicts a laser perforation 68 having one or more laser generators 70.In order to generate and direct a pulsed laser beam 74 in a transversedirection across the substrate 14 as the substrate moves continuously inthe longitudinal traveling direction, a relatively high speed rotarymirror 72 may be utilized to direct the beam 74 in a back-and-forthtraversing path between the edges 57 of the substrate, as depicted bythe double-arrow line in FIG. 4.

A laser perforation machine 68 has distinct advantages. For example,with a mechanical cutter, the perforation blades produce a varyingperforation characteristic as the blades dull with use. The laser doesnot dull. Also, mechanical (blade) perforation characteristics arenon-uniform depending on which side of the web the puncture begins, asfibers are compressed downward as the blade penetrates the paper. Alaser provides more symmetric characteristics as the web is severedcleanly and uniformly from top to bottom without compression of thefibers.

As depicted in FIG. 3, it may be desired to include real-time feedbackto the laser machine 68 that is used to vary laser intensity. Forexample, a sensor 55 may be utilized to detect light transmitted throughthe perforation line, wherein the amount of light detected is anindication of perforation characteristics. Such feedback can be used tovary the laser intensity to achieve an even greater uniformity of theperforation line.

FIGS. 5 and 6 are provided to illustrate the concept of differentperforation profiles 64 between the adjacent ends of interconnectedlottery tickets 52. The differences between the profiles 64 result fromthe duration and intensity of the pulsed laser 74. The longer the “on”time of the laser 74 and/or the intensity (power) of the laser, thelonger or wider are the holes defined through the substrate 14(indicated by the dark portions of the perforation line 58 in FIGS. 5and 6). Likewise, the longer the “off” time of the pulsed laser 74, thegreater is the amount of substrate that remains intact between theholes. Thus, the operation of the laser generator 70 is controlled inaccordance with one of the perforation profiles 64 to achieve thetailored perforation line 58 having the desired strength profile.

It can be appreciated from FIG. 6 that the perforation profile 64 neednot be uniform across the entire perforation line 58. The present systemand method provide the unique benefit to tailor discrete specificsections or portions of the perforation line 58. For example, asdepicted in FIG. 6, it may be desired to provide the extreme ends of theperforation line 58 with an initial elongated tear or separated portionin order to ensure that subsequent tears to separate the tickets 52propagate along the perforation line 58 and require a reduced initialtear force.

Aspects of the present method and system refer to a “controller”, asdiscussed above. The term “controller” is used herein to encompass anyconfiguration of computer hardware and software that is maintained tocarry out the functionalities of the present system and associatedmethod, as well as any manner of additional lottery functions known tothose skilled in the art. It should be readily appreciated that thecontroller 62 may include an integrated server, or any manner ofperiphery server or other hardware structure. The controller 62 mayinclude a memory for storing operating procedures and routines relatedto the perforation machine, a memory for the library 66 of storedperforation profiles 64, a microprocessor (MP) for executing the storedprograms 64, a random access memory (RAM) and an input/output (I/O) bus.These devices may be multiplexed together via a common bus, or may eachbe directly connected via dedicated communications lines, depending onthe needs of the system 10.

The controller 62 may be directly or indirectly connected through an I/Obus to any manner of peripheral devices such as storage devices,wireless adaptors, printers, and the like. In addition, a database (DB)may be communicatively connected to the controller 62 and provide a datarepository for the storage and correlation of the perforation profiles64 with particular values of the control variables 60.

The material particularly shown and described above is not meant to belimiting, but instead serves to show and teach various exemplaryimplementations of the present subject matter. As set forth in theattached claims, the scope of the present invention includes bothcombinations and sub-combinations of various features discussed herein,along with such variations and modifications as would occur to a personof skill in the art.

What is claimed is:
 1. A system for producing a perforation line betweenadjacent lottery tickets in an automated production line wherein asubstrate is conveyed through a perforation station in the productionline, the substrate having individual lottery ticket indicia printedthereon such that a continuous stream of adjacent lottery ticketsoriented end-to-end are conveyed through the perforation station, thesystem comprising: a perforation machine at the perforation station toproduce a perforation line between the adjacent lottery tickets; acontroller in communication with the perforation machine, wherein thecontroller is configured to: receive inputted control variables thatrelate to conditions that determine a desired perforation profile of theperforation line; program the perforation machine to produce theperforation line with a specific perforation profile based on theentered control variables; reprogram the perforation machine with adifferent perforation profile upon receipt of different values for thecontrol variables; and wherein the control variables relate toenvironmental conditions expected at a dispensing location for thelottery tickets being produced and the perforation profiles are changedbetween different ticket production runs, or between tickets in the sameticket production run based on changes in the environmental conditions.2. The system according to claim 1, wherein the control variables areone or both of temperature and humidity at the dispensing location. 3.The system according to claim 1, wherein the control variables relate toa combination of the environmental conditions expected at the dispensinglocation of the lottery tickets and characteristics of a substrate stockon which the lottery tickets are printed in the production line.
 4. Thesystem according to claim 1, further comprising an electronic library ofdifferent pre-generated perforation profiles for specific values of thecontrol variables, the controller in communication with the library,wherein the controller selects one of the pre-generated perforationprofiles that is a closest match for the input control variables.
 5. Thesystem according to claim 4, wherein the controller further modifies theselected pre-generated perforation profile based on the input controlvariables.
 6. The system according to claim 1, wherein the perforationmachine is a laser perforation machine having one or more laserperforation heads that are controlled by the controller for producingthe different perforation profiles.